Electric Arc Welding

Arc welding is that process in which the pieces of the metal to be welded are brought to the proper welding temperature at a point of contact by the heat liberated at the arc terminals and in the arc stream so that the metal pieces are completely fused into each other, forming a single solid homogeneous mass, after it solidifies. In this process an electric arc is produced by bringing two conductors (electrode and metal piece) connected to a suitable source of electric current momentarily in contact and then separating by a small distance. The current continues to flow across the small gap and gives intense heat. The heat developed is utilized to melt the part of the work piece, and the filler metal and thus form the joint. So arc welded joint is a union of metal parts made by localized heating without any pressure. That is why sometimes this type of welding is known as the non-pressure welding. The heat developed by arc is also used for cutting of metal. The voltage necessary to strike the arc is higher than that required to maintain it. The temperature is of the order of 3600°C, at which mechanical pressure is not required for jointing. According to B.S.S. 638 maximum voltage specified for welding is about 100 volts for the safety of the operator. The arc voltage varies from 20 to 40 volts and current from 50 A in sheet metal work to 1000 A in heavy automatic welding. The electric arc welding is widely used for joining of metal parts, the repair of fractured castings and fillings by the deposition of new metal on the worn-out parts. The welding circuit essentially consists of a welding machine, two leads, an electrode holder, an electrode and the work itself.

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